Removal and Installation
Main Bearing, Crankshaft and Cylinder Block Removal and Installation
Main Bearing, Crankshaft and Cylinder Block Components
NOTE:
If any of the parts listed below is reinstalled into a position different from the original position, engine problems could occur.
If these parts are to be reused, keep them in numerical order so that they may be reinstalled in their original positions.
- Main bearing
- Thrust bearing
NOTE:
For identification of each cylinder, refer to Precautions for Identification of Cylinder Precautions for Identification of Cylinder.
Removal
1) Remove engine assembly. Removal and Replacement
2) Remove flywheel for M/T model or drive plate for A/T model. Flywheel / Drive Plate Removal and Installation
3) Remove generator. Generator Removal and Installation
4) Remove water pump. Water Pump Removal and Installation
5) Remove P/S pump. P/S Pump Removal and Installation
6) Remove engine front mounting brackets (1).
7) Remove piston and connecting rod. Removal and Installation
8) Remove oil pump chain adjuster (1) from lower crank case.
9) Remove CKP sensor. CKP (Crankshaft Position) Sensor Removal and Installation
10) Loosen crank case bolt No.2s in numerical order ("1" - "12") evenly and gradually.
11) Loosen crank case bolt No.1s in numerical order ("1" - "10") evenly and gradually, and then remove lower crank case and rear oil seal.
NOTE:
Use 12-point socket wrench to crank case bolt No.1s.
12) Remove crankshaft and oil pump chain from cylinder block.
13) Remove sensor plate (2) from crankshaft (1), if necessary.
NOTE:
Use T-30 security TORX� to loosen sensor plate screws (3).
Installation
Crankshaft Inspection
Main Bearing Inspection
Sensor Plate Inspection
Flywheel / Drive Plate Inspection
Cylinder Block Inspection
Oil Pump Drive Sprocket Inspection
Oil Pump Chain and Oil Pump Chain Adjuster Inspection
NOTE:
- The engine will seize up if it is operated when the parts listed below are not properly lubricated.
Be sure to lubricate all the friction surfaces of these parts with engine oil before installing them.
- Crankshaft journal
- Main bearing
- Thrust bearing
- Oil pump chain guide
- If oil is present between the bearing's outside surface and the cylinder block / lower crank case surface, the bearing could heat up to very high temperature, resulting in seizure.
Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface and the cylinder block / lower crank case surface.
1) Install sensor plate (1) according to the following procedure.
a) Attach spring pin (2) to crankshaft (3).
NOTE:
Use spring pin which is genuine SUZUKI part (09205-05006).
b) Install sensor plate to crankshaft, fitting pin into hole (4) and facing inside edge (5) outward as show in figure.
Tightening torque
Sensor plate screw (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
c) Detach spring pin from crankshaft.
2) Install main bearings to cylinder block and lower crankcase according to the following procedure.
NOTE:
- Install main bearing halves with oil groove to cylinder block.
- Install other main bearing halves to lower crankcase.
a) Fit the tab (1) on each bearing into recess (2) in cylinder block or lower crank case.
b) Press bearing end (3) until it fully seat in cylinder block or lower crankcase.
c) Apply engine oil to sliding surface (4) of main bearing halves.
NOTE:
If oil is present between the bearing's outside surface and the camshaft housing / cylinder head surface, the bearing could heat up to very high temperature, resulting in seizure.
Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface (5) and the camshaft housing / cylinder head surface.
3) Install new O-rings (1) to cylinder block (3).
4) Install dowel pins (2) to cylinder block (3).
5) Apply engine oil to thrust bearings (1) and install them to cylinder block journal No.3, with oil grooves (2) facing outward.
6) Apply engine oil to sliding surface of main bearings and crankshaft.
7) Install crankshaft to cylinder block, with oil pump chain installed to oil pump drive sprocket on crankshaft.
8) Apply sealant to mating surface of lower crankcase (1) as shown in figure.
"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)
Sealant bead size for lower crankcase
Width "a": 3 mm (0.12 in.)
Height "b": 2 mm (0.08 in.)
9) Install lower crank case to cylinder block and tighten crank case bolt No.1s according to the following procedure.
NOTE:
- If crank case bolt No.1s are reused, check them for deformation referring to "Crank Case Bolt No.1 Inspection" under Main Bearing Inspection Main Bearing Inspection.
- Use 12-point socket wrench to crank case bolt No.1s.
a) Apply engine oil to bolt threads and seats of crank case bolt No.1 and tighten bolt to 50 Nm (5.1 kgf-m, 37.0 lbf-ft) in numerical order ("1" - "10") evenly and gradually.
b) Loosen all bolts in reverse numerical order until loosening torque becomes 0.
c) In the same manner as Step a), retighten them to 20 Nm (2.0 kgf-m, 15.0 lbf-ft).
d) In the same manner as Step a), retighten them to 35 Nm (3.6 kgf-m, 26.0 lbf-ft).
e) In the same manner as Step a), retighten them to 40°.
f) In the same manner as Step a), retighten them to 40°.
Tightening torque
Crank case bolt No.1* (a): (50 Nm -> 0 Nm -> 20 Nm -> 35 Nm -> 40° -> 40° (5.1 kgf-m -> 0 kgf-m -> 2.0 kgf-m -> 3.6 kgf-m -> 40° -> 40°, 37.0 lbf-ft -> 0 lbf-ft -> 15.0 lbf-ft -> 26.0 lbf-ft -> 40° -> 40°))
10) Tighten crank case bolt No.2s in numerical order ("1" - "12") evenly and gradually.
Tightening torque
Crank case bolt No.2* (a): 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
11) Check that crankshaft rotates smoothly when turning it by hand.
12) Apply engine oil to new rear oil seal (1) and install it to cylinder block (2) using special tools.
Special Tool
(A): 09911-97710
(B): 09911-97811
13) Install pistons and connecting rods. Removal and Installation
14) Install oil pump chain adjuster (1).
Tightening torque
Oil pump chain adjuster bolt (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
15) Install CKP sensor. CKP (Crankshaft Position) Sensor Removal and Installation
16) Install flywheel for M/T model, or drive plate for A/T model. Flywheel / Drive Plate Removal and Installation
17) Install engine front mounting brackets (1).
Tightening torque
Engine front mounting bracket bolt (a): 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
18) Install P/S pump. P/S Pump Removal and Installation
19) Install water pump. Water Pump Removal and Installation
20) Install generator. Generator Removal and Installation
21) Install engine assembly. Removal and Replacement